Process for assembling a double-sided circuit component

Title: Process for assembling a double-sided circuit component

Related Patent Categories: Semiconductor Device Manufacturing: Process, Packaging (e.g., With Mounting, Encapsulating, Etc.) Or Treatment Of Packaged Semiconductor, Assembly Of Plural Semiconductive Substrates Each Possessing Electrical Device, Stacked Array (e.g., Rectifier, Etc.)

Brief Patent Description - Full Patent Description - Patent Claims

The Patent Description & Claims data below is from USPTO Patent Application 20060189032, Process for assembling a double-sided circuit component.

1. A process of producing a double-sided circuit component, the process comprising: depositing a solder material on surfaces of first and second substrate members, each of the first and second substrate members being formed of an electrically-nonconductive material and comprising at least one electrically-conductive area on the surface on which the solder material is deposited; placing the first substrate member within a cavity in a receptacle; placing a lead member on the first substrate member so that the lead member is supported by the receptacle and a portion of the lead member is aligned with a portion of the electrically-conductive area of the first substrate member; placing a fixture on the lead member and over the first substrate member so that the fixture is supported by the receptacle; aligning a circuit device with the electrically-conductive area of the second substrate member to yield a preliminary assembly; placing the preliminary assembly in an aperture in the fixture so that a first surface of the circuit device electrically contacts the electrically-conductive area of the first substrate member and a second surface of the circuit device electrically contacts the electrically-conductive area of the second substrate member, thereby yielding a fixtured assembly comprising the first and second substrate members, the receptacle, the lead member, the fixture, and the circuit device; heating the fixtured assembly to cause the solder material to melt, flow, and wet the electrically-conductive areas of the first and second substrate members, the portion of the lead member, and the first and second surfaces of the circuit device; and then cooling the fixtured assembly to yield the double-sided circuit component in which the electrically-conductive area of the first substrate member is solder bonded to the first surface of the circuit device, the electrically-conductive area of the second substrate member is solder bonded to the second surface of the circuit device, and the portion of the lead member is solder bonded to the first and second substrate members so as to be electrically coupled with at least one of the electrically-conductive areas of the first and second substrate members.

2. The process according to claim 1, wherein during the step of placing of the lead member on the first substrate member and the receptacle, the lead member is located on the receptacle with location pins on the receptacle.

3. The process according to claim 1, wherein the first substrate member is supported within the cavity of the receptacle with recessed pedestals within the cavity.

4. The process according to claim 1, wherein the second substrate member is supported within the aperture of the fixture with pedestals within the aperture.

5. The process according to claim 1, wherein the fixture contacts and immobilizes the lead member adjacent the portion thereof.

6. The process according to claim 5, wherein the fixture contacts and immobilizes a region of the lead member oppositely disposed from the portion thereof.

7. The process according to claim 1, wherein during the heating and cooling steps the receptacle supports the first and second substrate members, the lead member, the fixture, and the circuit device solely under the force of gravity.

8. The process according to claim 1, wherein the circuit device is a field effect transistor, the first and second surfaces of the circuit device contain a source, gait and drain of the field effect transistor, and the process results in the source, gait, and drain being solder bonded to separate electrically-conductive areas on the surfaces of the first and second substrate members.

9. The process according to claim 1, wherein the double-sided circuit component is one of a plurality of substantially identical double-sided circuit components produced with the fixture and the receptacle during the process.

10. A process of producing a double-sided circuit component, the process comprising: depositing a solder paste on surfaces of first and second substrate members, each of the first and second substrate members being formed of an electrically-nonconductive material and comprising at least one electrically-conductive area and a plurality of bond pads on which the solder paste is deposited; placing the first substrate member within a cavity in a receptacle; placing a pair of lead members on the receptacle so that a portion of each of the lead members is individually aligned with one of the bond pads of the first substrate member; placing a fixture on the lead members and over the first substrate member so that the fixture is supported by the receptacle; aligning a circuit device with the at least one electrically-conductive area of the second substrate member to yield a preliminary assembly; placing the preliminary assembly in an aperture in the fixture so that at least one electrode on a first surface of the circuit device electrically contacts the at least one electrically-conductive area of the first substrate member, at least one electrode on a second surface of the circuit device electrically contacts the at least one electrically-conductive area of the second substrate member, and the portions of the lead members are between aligned pairs of the bond pads of the first and second substrates, thereby yielding a fixtured assembly comprising the first and second substrate members, the receptacle, the lead members, the fixture, and the circuit device; heating the fixtured assembly to cause the solder paste to melt, flow, and wet the electrically-conductive areas and the bond pads of the first and second substrate members, the portions of the lead members, and the electrodes on the first and second surfaces of the circuit device; and then cooling the fixtured assembly to yield the double-sided circuit component in which the at least one electrically-conductive area of the first substrate member is solder bonded to the at least one electrode on the first surface of the circuit device, the at least one electrically-conductive area of the second substrate member is solder bonded to the at least one electrode on the second surface of the circuit device, and the portions of the lead members are individually solder bonded to the pairs of the bond pads of the first and second substrate members.

11. The process according to claim 10, wherein during the step of placing of the lead member on the first substrate member and the receptacle, the lead member is located on the receptacle with location pins on the receptacle.

12. The process according to claim 10, wherein the first substrate member is supported within the cavity of the receptacle with recessed pedestals within the cavity.

13. The process according to claim 10, wherein the second substrate member is supported within the aperture of the fixture with pedestals within the aperture.

14. The process according to claim 10, wherein the fixture contacts and immobilizes the lead members adjacent the portions thereof.

15. The process according to claim 14, wherein the fixture contacts and immobilizes a region of the lead members oppositely disposed from the portions thereof.

16. The process according to claim 10, wherein during the heating and cooling steps the receptacle supports the first and second substrate members, the lead members, the fixture, and the circuit device solely under the force of gravity.

17. The process according to claim 10, wherein the circuit device is a field effect transistor, the first and second surfaces of the circuit device contain a source, gait and drain of the field effect transistor, and the process results in the source, gait, and drain being solder bonded to separate electrically-conductive areas on the surfaces of the first and second substrate members.

18. The process according to claim 10, wherein the double-sided circuit component is one of a plurality of substantially identical double-sided circuit components produced with the fixture and the receptacle during the process.

Brief Patent Description - Full Patent Description - Patent Claims

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Semiconductor device manufacturing: process

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